Dept.

Approved Checked Approved

PROCESS-SPECIFIC WASTE By By By

Section: IDENTIFICATION CHECKLIST

Note - Magnitude of waste (on a scale of 1 to 3)

i. 1: A little waste
ii. 2: Moderate waste
iii. 3: A lot of waste

TYPE CONFIRMATION CAUSES AND

OF DESCRIPTION OF WASTE MAGNITUDE IMPROVEMENT
WASTE YES NO PLANS

1. No production schedule or control

boards

2. No leveling of production schedule

3. Production not in sync with

production schedule
Type 1. Overproduction

4. Items missing

5. Defective goods produced

6. Equipment breakdowns

7. Too much manual assistance

8. Too much capacity

9. Lots grouped into batches

10. Using ”push production“

11. Caravan-style operations

12. Not balanced with next process

1. Lots of inventory on shelves and

floors

2. Shelves and floor storage take up lots

of space

3. Inventory stacks block walkways

Type 2. Inventory

4. In-process inventory accumulates

within individual operations

5. In-process inventory is stacked up

between operators

6. In-process inventory is stacked up

between processes

7. Impossible to visually determine

quantities of in-process inventory
TYPE CONFIRMATION CAUSES AND
OF DESCRIPTION OF WASTE MAGNITUDE IMPROVEMENT
WASTE YES NO PLANS

1. Pile-up during conveyance

2. Change of conveyance devices in

Type 3. Transportation

mid-transfer

3. Previous and/or next process is on

another floor

4. Conveyance requires manual

assistance

5. Conveyance distance too long

Complaints from next process

2. Defect within process

3. Human errors

4. Defective due to missing part(s)

Type 4. Defects, Scrap &

5. Defective due to wrong part(s)

6. Omission in processing
Rework

7. Defect in processing

8. No human autonomotion

9. No poka-yoke

10. No inspection with process

11. Defects not addressed by

improvement activities

1. Process is not required for product

function
Type 5. Over-processing

2. Process includes unnecessary

operations

3. Process can be replaced by

something less wasteful

4. Part of process can be eliminated

without detracting from product
TYPE CONFIRMATION CAUSES AND
OF DESCRIPTION OF WASTE MAGNITUDE IMPROVEMENT
WASTE YES NO PLANS

1. Walking

2. Turning around

3. Leaning sideways

4. Leaning over

5. Wide-arm movements
Type 6. Motion

6. Wrist movements

7. Left or right hand is idle

8. Idle time used for observation

9. Workpiece set-up/removal

10. No standardized repetition of

operations

11. Worker operates using different

motions each time

12. Operations divided up into little

segments

1. Idle time due to workpiece delay from

previous piece

2. Idle time due to machine busy status

3. Idle time due to missing item(s)

Type 7. Waiting

4. Idle time due to lack of balance with

previous process

5. Idle time due to lack of planning

6. Idle time due to lack of standard

operations

7. Idle time due to worker absence

Total

Overall Improvement Comments: